Inventors:
Ronald C. Sahr - Randall MN, US
Michael D. Nelson - Little Falls MN, US
Robert L. Retka - Long Prairie MN, US
Assignee:
VEC INDUSTRIES, L.L.C. - 80 South 8th Street MN
International Classification:
B32B 37/10
Abstract:
A method for molding an article having an upper portion, a lower portion, and an insert located between the upper portion and the lower portion, wherein the article is molded as a single, unitary piece with no seams or discontinuities located between the upper portion and the lower portion, includes providing a first semi-rigid membrane removably mounted to a first rigid housing to define a first fluid tight chamber therein, providing a mold plenum defined at least in part by the first semi-rigid membrane removably mounted to the first rigid housing, filling the first fluid tight chamber with a substantially non-compressible backing fluid to support the first semi-rigid membrane during injection of resin, positioning the insert in the mold plenum, providing fibrous reinforcing material within the mold plenum, the fibrous reinforcing material including portions positioned between the first semi-rigid membrane and the insert, the fibrous reinforcing material portions positioned between the first semi-rigid membrane and the insert being in contact with the insert, injecting resin under pressure into the mold plenum such that the resin envelops the fibrous reinforcing material and the insert, distributing a resulting injection pressure by the backing fluid, and curing the resin by heating the backing fluid to produce the molded article.